Sharma 2019 J. Phys. Conf. Ser. 1240 012030

Journal of Physics: Conference Series
PAPER • OPEN ACCESS You may also like

- Implementation of Geographic Information
An Intelligent Simulation based case study of System for Micro, Small, and Medium
Enterprises (MSMEs) in Lampung
Indian Micro Small Medium Enterprise (MSME) of Province using Android Platform
A R Irawati, D Kurniawan, M Yusman et al.
farm equipment manufacturing - MSME (Micro Small Medium Enterprise)

development strategy with LED approach
in the Dolly ex-red light district
To cite this article: Janpriy Sharma and Arvind Jayant 2019 J. Phys.: Conf. Ser. 1240 012030 B U Aulia and V K Siswanto
- The Benefits of Energy Efficiency in Small

and Medium Enterprises
Shankara Naik and S B Mallur
View the article online for updates and enhancements.
This content was downloaded from IP address 49.206.20.247 on 30/12/2021 at 07:11

NFEST IOP Publishing
IOP Conf. Series: Journal of Physics: Conf. Series 1240 (2019) 012030 doi:10.1088/1742-6596/1240/1/012030
An Intelligent Simulation based case study of Indian Micro

Small Medium Enterprise (MSME) of farm equipment
manufacturing
Janpriy Sharma1, Arvind Jayant2

Department of Mechanical Engineering, Sant Longowal Institute of Engineering and
Technology, Longowal Distt. Sangrur, Punjab, INDIA.
arvindjayant@gmail.com, arvindjayant@sliet.ac.in
Abstract. The manufacturing field is the area where application of simulation is an essential tool
for validating the methods and architecture before applying them to factory shop floor. In this
paper an Indian Micro Small Medium Enterprise (MSME) is taken into consideration, which
manufactures agricultural equipment’s with aim to mechanise the Indian farming techniques.
Presented case study is authentic and adopted for Gahir Agro Industries situated in agricultural
hub, state of Punjab. Proposed company is all set to launch a new farm equipment called ‘Laser
Land Leveller’ which got approval from governing body and ready for its batch production
because of seasonal demand. Present study encapsulates the modelling and simulation as tool for
analysis of manufacturing process of laser land leveller and its predicted production levels under
actual working conditions. Tool used for modelling and simulation is ARENA 15.1 by Rockwell
Automation Studio.
Keywords – Modelling, Simulation, MSME, Laser land Leveller, Seasonal Industry, ARENA
1. Introduction
Micro Small Medium Enterprise (MSMEs) sector has developed as emerged as highly vibrant and
dynamic sector of the Indian economy over the last five decades. MSMEs contribute nearly 8% of the
country GDP 45 percent of the manufacturing output and 40 percent of the exports. They provide the
largest share of employment after agriculture. MSME not only play crucial role in providing large
employment opportunities at comparatively lower capital cost than large industries but also help in
industrialization of rural & backward areas, thereby, reducing regional imbalances, assuring more
equitable distribution of national income and wealth. MSME are complementary to large industries as
ancillary units and this sector contributes enormously to the socio-economic development of the country
(Katyal and Xaviour 2015). MSMEs are situated in suburban or rural area and do not have much
exposure to the emerging trends of manufacturing, marketing, demand forecasting, material handling
and logistics, struggle to withstand globalisation as well as fluctuating governing norms and policies. In
this study industry considered is an ISO certified MSME situated in agricultural activity dominating
area of Sangrur (Punjab) manufacturing farm implement namely laser land leveller which is combination
of mechanical and laser beam-based technology. Company is all set to go for its production as per
customer demand after getting necessary approvals form the governing bodies. Using modelling and
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
simulation as tool for evaluating the production volume scenarios of laser beam land leveller and
solution to many if-then situations which arise generally before starting of mass production is provided
in scientific way under feasible constraints. Tool used for modelling and simulation is ARENA 15.1.
this study will be covering all the working aspects and resources utilisation with predicted work out to
input ratio, with aim to strengthen production network and revolutionise the poor R&D and production
system of MSMEs.
2. Literature Review
A vast literature supporting the challenges and barriers for the Indian MSMEs is available. (Kumar and
Subramanya 2010) Founded that Trans-national corporations (TNCs) expand their production bases to
developing countries having better conditions of manufacturing and domestic markets provide
increasing opportunities for local small and medium enterprises (SMEs) to have subcontracting
relationships with these TNCs. Resulted that substantiates in the Indian context that subcontracting
relationship with a TNC can be an important source of technological innovations and enhanced
economic performance for SMEs (Chawan and Vasudev 2014) done analysis of connection between
many organizations like ministries / government departments, bilateral & multilateral agencies,
academic, research & development institutions, implementing & executing agencies and industrial
associations was framed and its importance was explained. (Anuradha et. al 2014) attempted to critically
analyse the definitional aspect of MSMEs and explore the opportunities enjoyed and the constraints
faced by them in the era of globalization. (Kumar and Singh 2015) studied the need of supply chain
management for giving an edge to MSMEs overview their competitors for overall improvement. Found
13 critical success factors in implementation of supply chain to measure improvement in performance,
the authors considered different measures related to customer service and satisfaction, innovation and
growth, financial performance, and internal business. Results were analyses by testing research
propositions using standard statistical tools. (Thanki and Govindam 2016) used analytical hierarchy
process approach to investigate the impact of select lean and green practices on performance benefits,
and to evaluate the influence of lean and green paradigms on overall performance of SMEs. Developed
an integrated framework for lean-green system to guide SMEs towards sustainable growth. (Verma and
Sharma 2017) Studied the implementation of lean manufacturing for improving quality and productivity
on small scale MSMEs. Identified waste related problems, cause of equipment failure, bottleneck
problems and rectify them. The above problems were analysed in concern with rejection control,
inventory control, waiting time, set time and eliminating non-value-added time / activities. The complete
problem was identified and depicted by value stream mapping. Suggested improvements and
implementation of lean tools in small scale industry in terms of reduced wastage and high productivity.
(Sahoo and Yadav 2018) investigated the relationship between quality management dimension and firm
performance, considering manufacturing SMEs as focal point of research. Studied barriers in the
implementation of quality management prospects in manufacturing SMEs. Data for 127 manufacturing
Indian SMEs was drawn to addresses the research objective. Test of the structural model supports the
proposed hypothesis, that TQM related to manufacturing performance.
Anjali et al. (2009) Presented a layout of Automated guided manufacturing systems with four machines,
2 AGV, one loading/unloading zone and one parking station for AGV recharging facilities. For the given
layout simulation was performed for parts scheduling and routing by Arena Software. Result produced
gave the best scheduling policy for parts sequencing, part dispatched by AGVs and part processing at
machines. Nancy Ruiz et al. (2014) Studied application of Simulation process in manufacturing field
used SimlSHOP as simulation tool which includes the tasks like model creation, simulation, animation
and distribution of elements. Simulation result validated that agent supported architecture for simulation
and an intelligent manufacturing meta-model proposed was working well with requirements of new
manufacturing era and provided enough flexibility for designing complex models and experiments.
Jayant et al. (2014) studied reverse logistic network and sustainable supply chain systems of used
inverter batteries collection in North India aim was to model and simulate the reverse logistic network
for collection of EOL products for XYZ industry. Tool used for modelling & simulation was Arena
2
software (11.0) by Rockwell animation studio to find solution to problem areas identified and to improve
reverse logistic operation. Nyemba et al. (2017) Studied the dynamic factors impacting the movement
of materials within manufacturing environment, complexity in assembling owing to the multiplicity and
interconnectedness of these factors. Presented a case study of a furniture manufacturing and timber
processing industry having batch production tool used for this problem was modelling and simulation
by ARENA software. This paper corporates small level MSME which is manufacturing agricultural
equipment and demand is seasonal. Gahir Agro industries of Punjab is upcoming with production of
laser land leveller, by using modelling and simulation as tool based on existing setup of company its
expected production volume, resources utilisation level will be explored. Tool used for modelling and
simulation is ARENA 15.1 by Rockwell Automation Studio.
2.1. Micro Small Medium Enterprise (MSMEs)

In accordance with the provision of Micro, Small & Medium Enterprises Development (MSMED) Act,
2006 the Micro, Small and Medium Enterprises (MSME) are classified in two Classes:
Manufacturing Enterprises- The enterprises engaged in the manufacture or production of goods
pertaining to any industry specified in the first schedule to the industries (Development and regulation)
Act, 1951) or employing plant and machinery in the process of value addition to the final product having
a distinct name or character or use. The Manufacturing Enterprise are defined in terms of investment in
Plant & Machinery.
Service Enterprises: -The enterprises engaged in providing or rendering of services and are defined
in terms of investment in equipment.
The limit for investment in plant and machinery / equipment for manufacturing / service enterprises is
as following.
Medium
Enterprises
Small Enterprises Investment* of
Investment* of more than 5 Crore
Micro Enterprise more than 25 Lakh rupee but less than
rupee but less than 10 Crore
Does not exceed
investment* of 25 5 Crore *Investment in
Lakhs terms of plant and
machinery
Figure 1 Classification of MSMEs of India
3. Research Methodology
• Tier 3 represents the most demanding part of research or laid foundation of research here by
using some selective keywords, phrases demanding need of research are used and on the basis
of which research literature is reviewed from data base. Papers which meet objectives are
accepted and details are checked for methodology opted.
• Tier 2 extends the works of tier 3 which allows to carry on with gaps found in literature by
checking references. If gaps formulated decision variables and chosen and scope of extension
is presumed.
• Tier 1 sum ups the work of tier 2 and tier 3 here actual work begins and its elaborated by
experimentation as here review of manufacturing process at industry chosen, usage of modelling
and simulation as tool for solving problem and at last summation of results and conclusion in
the form research paper, to guide other researchers.
3
Figure 2 Research Methodology
3.1 System analysis of Company - Gahir Agro Industries

Gahir Agro Industries Limited is an ISO 9001: 2008 certified organization that has introduced a
sophisticated range of Combine Harvesters and comes in the range of small enterprise out of MSMEs.
Company has successfully developed a range of Combine Harvesters (Tractor mounted and self-
propelled), rotavator (6 feet, 7 feet and 8 feet range) and Tractor Mounted Sprayer Pump. Company has
recently launched Laser land leveller for which they have taken approval from governmental
organizations. These organizations include Government of India Ministry of Agriculture (Department
of Agriculture & Co-Operation) Tractor Nagar, Punjab Agriculture University Ludhiana, Hisar and
Central Farm Machinery Training & Testing Institute Budni (Madhya Pradesh). After getting mandatory
approvals company is all set to start production of laser land leveller. Laser land leveller demand is
seasonal and accordingly its production plan too.
4. Laser Land Leveller

As per data provided by Department of soil and water conservation of state of Punjab, a significant (20-
25%) amount of irrigation water is lost during its application at the farm due to poor farm designing and
unevenness of the fields. This problem is more pronounced in case if rice fields. Fields that are not level,
have uneven crop stands, increased weed burden and uneven maturing of crops. All these factors leas to
reduced yield and poor grain quality. Solution to this problem is using combination of mechanical and
electronics-based Laser land levelling and equipment used for this designated purpose is known as Laser
land. Leveller.
Laser Land Levelling (also known as Laser Levelling) is a process of smoothening the land surface
from its average elevation with a certain degree of desired slope using a guided laser beam through out
the field. Unevenness of the soil surface has a significant impact on germination, stand and yield of
crops. Farmers also recognise this and therefore devote considerable time resources in levelling their
fields properly. However, traditional method of levelling is cumbersome, time consuming as well as
expensive.
4
Figure 3 Laser Land Leveller (Manufactured by Gahir Agro Industry)
4.1 Components in Laser Land Leveller

A laser-controlled land levelling system consists of the following five major components:
i. Drag Scrapper/bucket: The drag bucket can be either 3-point linkage mounted on or pulled
by a tractor. This system is preferred as it is easier to connect the tractor’s hydraulic system
to an external hydraulic by the 3-point-linkage system.
ii. Laser transmitter: The laser transmitter mounts on a tripod, which allows the laser beam to
sweep above the field.
iii. Laser receiver: The laser receiver is a multi-directional receiver that detects the position of
the laser reference plane and transmits this signal to the control box.
iv. Control box: The control box accepts and processes signals from the machine mounted
receiver. It displays these signals to indicate the drag buckets position relative to the finished
grade.
v. Hydraulic system: The hydraulic system of the tractor is used to supply oil to raise and
lower the levelling bucket.
Figure 4 Detail of components in laser land leveller Figure 5 Basic Layout of Laser Land Leveller
5
4.2 Working of Laser Land leveller

The system includes a laser-transmitting unit that emits an infrared beam of light that can travel up to
700 meters in a perfectly straight line. The second part of the laser system is a receiver that senses the
infrared beam of light and converts it to an electrical signal. The electrical signal is directed by a control
box to activate an electric hydraulic valve. Several times a second, this hydraulic valve raises and lowers
the blade of a grader to keep it following the infrared beam. Laser levelling of a field is accomplished
with a dual slope laser that automatically controls the blade of the land leveller to precisely grade the
surface to eliminate all undulations tending to hold water. Laser transmitters create a reference plane
over the work area by rotating the laser beam 360 degrees. The receiving system detects the beam and
automatically guides the machine to maintain proper grade. The laser can be level or sloped in two
directions. This is all accomplished automatically without the operator touching the hydraulic controls
Figure 6 Working of Laser land leveller
5. Technical Specifications of Laser land leveller

Proposed industry manufactures laser land levellers with specifications as
• Width: 7 feet
• Thickness: 8 mm/10 mm (mm = Millimetres)
• Mast: Gear / Power
• Blade: L – 84”, H – 127 mm, T – 16 mm
• Tyres: 6 – 16 SL
• Hydraulic Cylinder: Double Acting Heavy-duty Cylinder
5.1 Manufacturing process of laser land leveller

Manufacturing process of laser land leveller comprises of 3 main process which have distinct processes
and Sub process associated with it. Raw material required initially consist of metal sheets of thickness
(5 mm, 10 mm) which are cut, bent and shaped as per specifications. Details of all processes is appended
in figure 7.
Main processes are
i. Bucket/Scrapper manufacturing
ii. CURVO and Draw bar manufacturing
iii. Final assembly of manufactured products
6
•Sub Processes
STEP 1
•Metal Sheet Cutting
Scrapper/Bucket •Sheet Bending
Manufacturing •Assembling and Welding of
Sheets
•Sub Processes
STEP 2
•CURVO mounting
CURVO and Draw •Rear Axle mounting
Bar Manufacturing
•Painting
•Sub Processes
STEP 3 •Overall
Final Assembly
Assembly •Mast mounting
Figure 7 Manufacturing processes and subprocesses of laser land leveller manufacturing
6 Modelling and Simulation

Modelling represents the key characteristics, behaviours and functions of the selected physical or
abstract system or process. Simulation refers to intimate of the operation of a real-world process or
system. The model represents the system itself, whereas the simulation represents the operation of the
system over time.
Model can be physical or mathematical which is based on the real system which is under consideration.
Modelled part is looked for its suitability in compliance with real system. Simulation undertakes the
developed model check for its functionality under real working conditions, briefly it is intimate of
original system. Getting simulation runs and its working behaviours verify model and validate the
system under account.
6.1 Modelling and Simulation Tool – ARENA Overview
Figure 8 Simulation process – Overview
Tool used for modelling and simulation in this study is ARENA 15.1 version by Rockwell Automation
Studio. One of Arena’s most beneficial traits is that users across the whole spectrum of skill-levels can
use the product to generate useful results. This robustness is achieved by expanding upon an evolved
version of the SIMAN language, meaning that Arena has been built upon the shoulders of an already
successful product. Arena allows users to choose from various modules that are presented in various
templates ranging from basic logic pieces to complex items such as conveyers and transporters Each
7
module represents a combination of SIMAN code that has been pre-packaged to allow the user to drag
and drop pieces of code into the model without having to work with the code itself.
7 Case Study: Modelling And Simulation Of Laser Land Leveller Process

As Gahir Agro industry is ready to begin for its production of laser land leveller, after getting mandatory
approvals form the regulating and governing bodies of this field. Major consumers of laser land leveller
are in agriculture rich states of Punjab, Haryana, Uttar Pradesh and Telangana. This study will be
analysing the the production process, resources utilisation, predicted work in process, seizing capacity
of various processes and sub processes associated with manufacturing and number in and number out
by using ARENA 15.1 version as modelling and simulation tool. Presented work will be guiding
manufacturers about their predicted performance and bottlenecks in existing setup without going for
actual trial. Generated results are well validated and verified for their correctness. As for, in deepening
the manufacturing process of each stage, efforts are done for individual process modelling and
simulation with collaboration of its sub activities. All processes as in figure 6 have being modelled and
simulated to their full potential.
7.1 Assumptions for modelling and Simulation

i. Customer demand arrival follows the uniform distribution UNIF [15,20] in the batch of 5.
ii. Company has single tractor mounted crane which is used for inter shop transfer and has speed of
15 km/hr.
iii. It is assumed that all necessary spares and parts are available for assembly to product being
manufactured.
iv. Production timings have constant value for distinct process.
v. Once process is completed finished product is placed in buffer having First In First Out (FIFO)
sequence.
Table 1. Modelling logic of various manufacturing process
START Raw material arrival at

Demand Arrival
arrival dock
Request for transport of Tractor arrives picks raw material & deliver
STEP 1 at shop floor an
Scrapper/Bucket raw material to shop floor
Manufacturing made free for further use
Processing begins on raw material Plasma Cutting Sheet

Shop Floor area of sheets bending
Assembling and Request made for processed Tractor arrives

Welding material pick up to next destination pick done
Scrapper/bucket
Shop Exit taken manufacturing completes
8
Manufactured Required raw material

START Scrapper/Bucket arrives arrival at arrival dock
Request for transport to shop Tractor arrives picks raw material & deliver
STEP 2 floor for processing made at shop floor and made free for further use
CURVO/ Draw Bar
Manufacturing
Processing begins on raw material CURVO Single/Double
Shop Floor area mounting axle mounting
Request made for processed Tractor arrives

Painting
material pick up to next destination pick done
Shop Exit taken CURVO / Draw bar

manufacturing completes
Manufactured CURVO/ Required raw material

START
Draw bar arrives arrival at arrival dock
STEP 3
Final Assembly
Process Tractor arrives picks raw material & deliver
Request for transport to final
at final assembly area and made free for
assembly area made
further use
Final assembly begins on Shop Final Assembly MAST

Floor and Inspection mounting
Request made for finished Tractor arrives Shop Exit taken

product pickup pick done
Finished Product moved to

Laser Land Leveller ready
finished goods area and for customer use
stock checked
9
7.2 Modelling and Simulation of manufacturing of Laser Land Leveller Processes
7.2.1 SCRAPPER/BUCKET MANUFACTURING

I. This process begins with arrival of demand of customer and raw material in form of sheets
having thickness of (5 mm and 10 mm).
II. Firstly, raw material arrives at arrival dock of processing shop from where it is picked up by
tractor mounted crane and moved to shop floor where processing begins. Once raw material is
delivered by tractor mounted crane at shop floor, its made free for further use (Used Request,
Transport and Free module of ARENA).
III. Raw material is available at processing stations and firstly sheet is cut into various sizes by
plasma cutting machine deployed on shop floor, where it takes total of 3.5 hours. (Used Station
and Process module of ARENA)
IV. After cutting of sheet it is bend into required shapes by sheet bending machines and it takes total
of 3.5 hours (Used Process module of ARENA).
V. On completion of cutting and bending of sheets they are welded and assembled to make
scrapper/bucket which takes 2 hours (Used Process module of ARENA).
VI. On completion of operation sequences as mentioned above, manufactured scrapper/bucket takes
shop exit by requesting tractor mounted crane for its movement. (Used Request, Transport,
Station, Free and Dispose module of ARENA).
Table 2 Detail of Operation performed for Scrapper/Bucket Manufacturing
Operation Operation Name Operation Resources deployed

No. (In sequence of Timing
operation)
1 Plasma Sheet Cutting 3.5 hours Single Plasma Cutting

Machine
2. Sheet Bending 3.5 hours Single Sheet bending
machine
3. Assembling and Welding 2 hours Assembling of parts by
using Jigs and fixtures.
Welding by single arc and
single MIG welding set
Table 3 Inter Shop station distances for Scrapper/Bucket Manufacturing
Sr. No. Station Name (From) Station Name (To) Distance

(In Feet’s)
1. Arrival Dock Plasma Cutting Area 200

2. Plasma Cutting area Shop Exit 130
3. Arrival Dock Shop Exit 50
10
Table 4 Data related to Costing of Entity
Name of Entity Holding Cost/Hour Initial value-added Initial trans Cost

(In Rupee) cost (In Rupee) (In Rupee)
Laser Land 1.2 1100 1.3

Leveller
Figure 9 ARENA window depicting costing data of entity
Figure 10 ARENA window depicting complete model of Scrapper Bucket manufacturing
7.2.2 CURVO/DRAWBAR MANUFACTURING

i. Process begins with arrival of pre-manufactured scrapper/bucket and other raw material at
arrival dock (Used Create module)
ii. Request for transport to shop floor is made and material is transported to draw bar and Curvo
mounting station where processing occurs by tractor mounted crane. (Used Request, Transport
and Station module of ARENA)
iii. After delivering material at shop floor, processing begins and pre-assembled CURVO is
assembled there it takes 3.2 hours for single piece mounting. (Used Process module of ARENA)
11
iv. After CURVO mounting rear axle (Single/Double rear axle) is mounted with mounting time of
2 hours on each pre-assembled piece (Used Process module of ARENA).
v. After rear axle mounting painting is done by spray guns which take operation timing of 2.3
hours per piece. This include primer coating, primary paint coating and secondary coating (Used
Process module of ARENA).
vi. After painting manufactured CURVO/ Draw bar is ready to take shop exit and tractor
vii. mounted crane is requested for pick up when pick completes it takes shop exit and made free
for further use. (Used Request, Transport, Free, Station and Dispose module of ARENA)
Table 5 Detail of Operation performed for CURVO/ Draw Bar Manufacturing
Operation No. Operation Name Operation Timing Resources deployed

(In sequence of
operation)
1 CURVO Mounting 3.2 hours per piece Pre-Assembled Curvo
2. Rear Axle Mounting 2 hours per piece Single and Double Rear
Axle
3. Painting 2.3 hours 4 Painting spray guns
Table 6 Inter Shop station distances for CURVO/ Draw Bar Manufacturing

(In Feet’s)
1. Arrival Dock Draw bar and CURVO 200
mount
2. Draw bar and CURVO Shop Exit 150
mount
4. Arrival Dock Plasma Cutting area 130
Figure 11 ARENA window depicting distance between shops
12
Figure 12 ARENA window depicting modelling for CURVO/Draw bar manufacturing
7.2.3 Final Assembly and Mast Mounting

i. Manufactured Bucket/ Scrapper and CURVO/Draw Bar are taken at this station and final
assembly with inspection is done. (Used Create module of ARENA).
ii. Request for transport to shop floor is made and material is transported to final assembly area
where processing occurs by tractor mounted crane. (Used Request, Transport and Station
module of ARENA).
iii. After delivering material at shop floor, processing begins, and final assembly is done which
takes 2 hours per piece (Used Process module of ARENA).
iv. Last process comprises of mast mounting which takes 2 hours per piece (Used Process module
of ARENA).
v. Now laser land leveller is ready for customer use and it is taken to finished good area by
requesting tractor mounted crane to pick up and take it to finished area storage (Used Request,
Transport, Free and Station module of ARENA).
vi. Record module calculates the total finished product out for customer use. (Used Record and
Dispose module of ARENA).
Table 7 Detail of Operation performed for Final Assembly and Inspection
Operation Operation Name Operation Timing Resources deployed

No. (In sequence of operation)
1 Overall Assembly 2.5 hours per piece Assembly and Inspection

tools
2. Mast Mounting 2 hours per piece Pre-assembled mast
13
Table 8 Inter Shop station distances for Final Assembly and Inspection

(In Feet’s)
1. Arrival Dock Draw bar and CURVO 200

mount
2. Draw bar and CURVO Shop Exit 150
mount
4. Arrival Dock Plasma Cutting area 130
5. Arrival Dock Final Assembly Area 120
6. Arrival Dock Shop exit 60
Figure 13 Arena window depicting Station distance for Overall Assembly area
8 Results and Discussions

ARENA based results need to be validated and verified for there correctness. All the results generated
here are by latest ARENA 15.1 version installed on computer having 8 GB RAM, Intel i7 processor and
Window 10 (Pro) licensed version.
The random nature of simulation inputs renders the simulation run able to produce a statistical
estimate of the performance measure, not the measure itself. So that estimates can be statistically precise
(have a small variance) and free from the bias, the following parameters were specified.
• Length of each simulation run = 30 days (One Month)
• Number of independent simulation Runs = 60
• Work hours for which simulation done = 10 hours per day
8.1 Verification and Validation

Verification concerns the operational model (whether it is performing properly). It is done to ensure that
• The model is programmed correctly
• The model does not contain errors, oversights, or bugs.
In laser land levelling manufacturing process, model verification took place as a continuing process.
In this case percentage error is at an acceptable level of less than 5%.
Validation of Simulation runs - To make sure that model data accurately represent the actual process,
hence enhance model validity, a confidence interval analysis was carried out. A 95% confidence interval
was determined, and the required number of simulation replications were calculated by the following
equation (Kelton et al., 1991)
14
(𝐳 )𝟐 𝛔 𝟐
n= 𝛂/𝟐𝐝𝟐
where n = number of desired replications, d is the sensitivity level, σ = standard deviation (σ = 1.43), z
is the critical value form the standard normal table at the given confidence level (z = 1.96 at 95%
confidence level). For our model to achieve 95 % confidence level, 50 replications are required.
Validation of distribution used – Since simulation results are totally dependent on the, probabilistic
distribution used, in our model we used uniform distribution of [15,20] for demand arrival its goodness
of fit, statistical value will be validated and authenticated by inbuilt Input Analyser module of ARENA
shown in figure 14 (a) and 14(b).
Figure 14 (a) Input Analysis of Uniform distribution Figure 14 (b) Input analysis of distribution of [15,20] depicting statistical
[15,20] depicting goodness of fit data summary
It can be seen from figure 14(a) and 14(b) that mean square error of distribution used very less than 5%
i.e. 0.000144. Chi square test and Kolmogorov test value greater than 0.15 depict goodness of fit of
curve.
8.2 Results for Scrapper/Bucket Manufacturing
Predicted Number In/Out
Figure 15 Predicted Number In/Out
15
Figure 15 ARENA window depicting predicted Number in and Number Out at Scrapper/Bucket
Manufacturing Predicted number in for processing is 60, number Out will be 35 and work in process
will be 43 (approx..) for 50 replication length and 30 days run length.
Predicted Resources Utilisation
Figure 16 Arena window depicting predicted resources scheduled utilisation for scrapper/bucket
manufacturing
For the process of scrapper/bucket manufacturing plasma cutting machine predicted utilisation stands
for 52.08%, sheet bending machine predicted utilisation is 51.39%, Arc and MIG welding predicted
utilisation is 10.28% respectively and similar is for jigs and fixture predicted utilisation i.e. 10.28% for
50 replication and 30 days run length.
Number Seized by Resources
Figure 17 Arena window depicting predicted number seized by resources for scrapper/bucket
manufacturing
It can be seen from figure 17 that predicted total number of entities seized by Plasma cutting machine is
38, sheet bending machine is 37, MIG and arc welding is 37 respectively and for assembly purpose jigs
and fixture used seized 37 entities.
16
Costing data
Figure 18 Arena window depicting predicted costing of resource operation for 30 days run of
scrapper/bucket manufacturing
It can be seen from figure 18 that for 30 days run usage cost will be Rs. 78700, wait cost will be Rs.
16,811 and predicted overall cost will be 97,217 for manufacturing neglecting raw material cost.
8.3 Results for CURVO/ Draw Bar Manufacturing

Number In and Out
Figure 19 ARENA result window depicting predicted number in and number out for the various processes at CURVO/ Draw bar
manufacturing
17
In sight to above figure predicted number in for CURVO mount is 36 corresponding number out is also
36. For double axle and single mounting number in and number out is 36 respectively. Similarly, for
painting shop number in and number out will be 36 respectively. All these results are for 30 days run
length with 50 replications.
Waiting Queue Length
Figure 20 ARENA result window depicting predicted predicted waiting queue length for the various processes at
CURVO/ Draw bar manufacturing
In sight to above figure Arena predicted results yield that waiting queue will be only for painting process
and request for transport for the 50 replication and 30 days run.
Figure 21 ARENA result window for predicted costing of operating resources for
manufacturing of draw bar/ CURVO
Insight to above figure cost depicted here is excluding raw material cost and labour cost. It comprises
of expense of resources on manufacturing. It is predicted to be 41,400 for the 50 replications and 30
days run length.
18
8.4 Results for Overall Assembly and Inspection

Number In/Out
Figure 22 ARENA result window depicting predicted number in and number out for the various
processes at final assembling and inspection area of laser land leveller
As depicted in figure 22 predicted number in and number out is 60 respectively at final assembly area
and 60 number in and number out is for mast mounting station. These results are for 50 replications and
30 days run.
Scheduled utilisation of resources
Figure 23 ARENA result window depicting predicted resources utilisation and total number seized by
resources for final assembly and inspection of laser land leveller.
In reference to figure 32 predicted resources utilisation for the assembling of mast is 16.67% and for
final assembly tools it is 20.83%. these results are for 50 replication and 30 days run.
19
Number Seized by Resources
Figure 24 ARENA result window depicting predicted total number seized by resources for final
assembly and inspection of laser land leveller
In sight to figure 24 predicted total number seized by resources is as 60 for assembled mast, 60 for final
assembly tools.
Costing data
Figure 25 ARENA result window depicting predicted cost of operation of resources for final
assembly and inspection of laser land leveller
Figure 25 refers to the operation costing of the resources for the final assembly and inspection of laser
land leveller. It is valid for the 50 replications and 30 days simulation run.
20
Total number out of finished laser land leveller
Figure 26 ARENA result window depicting predicted number out of finished laser land leveller for
customer use
Figure 26 depicts the predicted value of total finished laser land leveller ready for customer use, which
is 35, when model is simulated for 60 replications and 30 days run length.
9 Conclusions And Recommendations

Approach taken here for MSMEs manufacturing process step wise modelling and simulation prior to
beginning of mass production, will be exploring the real time production scenario and its expected
outputs from existing shop floor. By using modelling and simulation as a tool without going for actual
production levels, an overview of production network is provided to company, which is not having any
well-defined research and development centre, production planning and controlling department which
regulate production lines. For in deep sights for each step of laser land leveller its major activities and
associated sub activities have been modelled and simulated, with predicted number in and number out
for each process, resources utilisation, waiting queue, operational cost of resources and number seized
by resources. All results are validated and verified for there correctness under working constraints.
Company can use these results to see bottlenecks, which hamper production scenario, in a predefined
manner with actual figures to over come those when actual production begins and in order to achieve
improved productivity targets.
Few improvements which can be visualised from the results generated are as follow
i. For step 1 of scrapper/bucket manufacturing resources utilisation is very high for plasma cutting
(0.52 approx.) and sheet bending (0.51 approx.) but lesser for welding and jigs fixture usage
(0.1028 approx.), which needs to be balanced.
ii. For Step 2 of draw bar/ CURVO mounting queue length is high for entities waiting at painting
shop (17 approx.) and pick up by tractor mounted crane (41 approx.) for next destination
transfer. Company need to work on these waiting queue so that resources utilisation can be
optimum and production volumes can be enhanced.
iii. For step 3 of final assembly and inspection, its potential of predicted work in (60) and out (60)
is more as compared to other processes but due to high waiting times and imbalanced utilisation
of resources in previous processes it is not being utilised to its full throttle. Resources utilisation
is very low here due to imbalanced production loads which is cause of high work in process (43
approx.) value of entities and widening the gap between number in and number out.
iv. Effective utilization of resources in terms of operation timing and seizing capacity of machine
is important as is affects the waiting cost, holding cost and processing cost of entities waiting
for operations, which tampers the profit margins and manpower working with it. In this waiting
cost was as high as Rs. 16,811 which needs to be curbed for achieving new horizons of
profitability.
Presented work here for the industry is flexible enough to accommodate changes at any level and its
effect on production volumes. Company can turn up their fortunes by implementing these suggestions
in order to achieve target value and better profit margins. Modelling and simulation can be boon for
these type of small MSMEs, which spend hefty money to check the expected outcomes of production
21
by experimenting with real setup, which also cause overflowing levels of inventory and mis management
on shop floor.
Analysis done here can help company to increase product throughput by reorganisation of process
flows and thus fulfilling customer orders on time and ultimately result in sustainable operations and
company growth. Implementation of these results is within working constraint limit of 10 hours per day,
which also enables mangers to gain insight of costly opinion of workers overtime depending upon need
of demand. Modelling and simulation results generated here provides a reasonable measure for
predicting performance and planning for production through experimenting on various what-if scenarios
which occurs prior to new product launch. The generated results were welcomed by company directors
and shown the glimpse of production scenario which would be and its expected output, now on the basis
of results shown directors can redesign their production strategy with more refinement to achieve high
profit margins, reduced lead time of demand fulfilment and utmost customer satisfaction and leading
edge over competitors of same field.
Work presented here can be validated by other simulation software like SimLShop, FlexiSIM etc.
Presented work can be extended by including the delay time of inventory accumulation and wait for
inventory availability on shop floor.
Acknowledgement
Deep sense of gratitude to Hon’ble Managing Director Mr Surjit Singh Gahir and Director
Production Er. Jagjeet Singh of Gahir Agro Industries Sangrur (Punjab). For providing opportunity to
carry out the project and extending their cooperation for data collection and providing all of support for
present research work. The authors are also thankful to the editor-in-chief and anonymous referees for
their constructive comments and valuable suggestions that explore new horizons in this field.
REFERENCES
1. Kumar, Ravinder, Rajesh K. Singh, and Ravi Shankar. "Critical success factors for
implementation of supply chain management in Indian small and medium enterprises and their
impact on performance." IIMB Management review 27, no. 2 (2015): 92-104.
2. Thanki, Shashank, Kannan Govindan, and Jitesh Thakkar. "An investigation on lean-green
implementation practices in Indian SMEs using analytical hierarchy process (AHP)
approach." Journal of Cleaner Production 135 (2016): 284-98.
3. Kumar, R. Sudhir, and MH Bala Subrahmanya. "Influence of subcontracting on innovation and
economic performance of SMEs in Indian automobile industry." Technovation 30, no. 11-12
(2010): 558-69.
4. Verma, Neha, and Vinay Sharma. "Sustainable competitive advantage by implementing lean
manufacturing “A Case study for Indian SME”." Materials Today: Proceedings 4, no. 8 (2017):
9210-17.
5. Sahooa, Saumyaranjan, and Sudhir Yadava. "Total Quality Management in Indian
Manufacturing SMEs." Procedia Manufacturing 21 (2018): 541-48.
6. Chawan, Anup, and Hari Vasudevan. "Knowledge Management Practices in Indian
Manufacturing MSMEs: Challenges and opportunities." Procedia Engineering 97 (2014):
1784-1787.
7. Katyal, Ashu, and Betsy Xaviour. "A Study on MSMEs’-Role in Propelling Economic
Development of India & a Discussion on current HR issues in MSMEs’ in India." International
Journal of Scientific and Research Publications 5, no. 2 (2015): 1-11.
8. Annuradha. J (2014) “Problems and Propsects of Micro, Small and Medium Enterprises
(MSMEs) in India in era of Globalisation” Quest Journal of Research in Business management,
6(2), 20-7.
22
9. Jay W Forrester (1968) “Industrial Dyanmics – After the First decade” Management Science,
14(7), 398-415.
10. K. Rota, C. Thierry (2002) “Supply Chain Management” Production Planning and Control,
13(4), 370-80.
11. Taha Al- Khudairi, Ibrahim Yahya Al Kattan (2007) " Improving Supply Chain Management
effectiveness using RFID" IEEE Xplore, 191-98, DOI: 10.1109/IEMC.2007.5235073.
12. Anjali Awasthi, S.S. Chauhan (2009) “ A Simulation model for parts selection and routing in
Manufacturing Systems” Proceedings of the 13th IFAC Symposium on Information Control
Problems in Manufacturing, 619-23.
13. J.S Baldwin, P.M. Allen, K. Ridgway (2010) “An evolutionary complex systems decsion
support tool for the management of operations” International Journal of Operation &
Production Management, 30(7),700-20.
14. N.V. Patel, T.E. Tariq, M. Khan (2010) “Theory of deferred action” Journal of Enterprise
Information Management, 23(4), 521-37.
15. W.R. Nyemba, T. Dzimba (2013) “The role of modelling and Simulation in decision making
for manufacturing enterprises” Proceedings of 5th International Conference on Manufacturing
Processes, Systems & Operation Management in Less Industrial Region, 11-21.
16. Harish, A. Kumar (2016) “A review on modelling and simulation of building energy systems”
Journal of Renewable and Sustainable Energy Reviews, 56, 1272-92.
17. D.R. Anderson, D.J. Sweeney, T.A. Williams, J.D. Camm, J.J. Cochran (2013) “Quantitative
Methods for business” Twelfth Edition South Western College Publishing Cincinnati.
18. A Negahban, J.S. Smith (2014) “Simulation for manufacturing system design and Operation:
Literature Review and Analysis” Journal of Manufacturing Systems, 33, 241-61.
19. Nancy Ruiz, Adriana Giret, Vicente Botti, Victor Feria (2014) “ An intelligent Simulation
environment for manufacturing systems” Computers & Industrial Engineering, 76, 148-68.
20. A Jayant, P. Gupta, S.K Garg (2014) “Simulation Modelling and analysis of network design for
closed loop Supply Chain: A case study of Battery Industry” Procedia Engineering, 97, 2213-
31.
21. Wilson R. Nyemba, Charles Mbohwa (2017) “Modelling, Simulation and Optimization of the
Materials flow of a multi-product assembling plant” Procedia Manufacturing, 8, 59-66.
22. C.W. Yeh, D.C. Li, Y.R. Zhang (2012) “Estimation of a data collection maturity model to detect
manufacturing change” Journal Expert systems with Applications, 39, 7093-01.
23. R. Bloomfield, E. Mazhari, J. Hawkins, Y.J. Son (2012) "Interoperability of Manufacturing
Applications using the Core Manufacturing applications using the Core Manufacturing
Simulation Data standard information model" Journal of Computers & Industrial Engineering,
62, 1065-79.
24. Kelton. D., Law, W. Averill (1991) "Simulation Modelling and Analysis" McGraw-Hill, New
York.
25. Morvin Savio Martis (2006) "Validation of Simulation based models: A Theoretical Outlook"
The Electronic Journal of Business Research Methods, 4(1), 39-46.
26. Magnus Wiktorson (2014) "Consideration of Legacy Structures enabling a double helix
development of Production Systems and Products" Technology and Manufacturing Process
Selection, Springer Series in Advanced Manufacturing.
27. E. Lefeber, R.A. Van den Berg and J.E. Rooda (2004) "Modelling, Validation and Control of
Manufacturing Systems" American Control Conference 2004.
28. Abdulziz M. El-Tamini, Mustufa H. Abidi, S. Hammad Mian, Javed Aalam (2011) "Analysis
of performance measures of flexible Manufacturing system" Journal of King Suad University-
Engineering Sciences, 24, 115-29.
23
29. Aksarayli, M., & Yildiz, A. (2011). Process optimization with simulation modelling in a
manufacturing system. Research Journal of Applied Sciences, Engineering and Technology,
3(4), 318-28.
30. Mourtzis, D. Doukas, M. Bernidaki (2014) "Simulation in Manufacturing: Review and
Challenges" CIRP Sponsored DET 2014 Conference, 25, 213-29.
24
Some text.
4.1.1. A subsubsection. The paragraph text follows on from the subsubsection heading but should not
be in italic.
References
[1] A reference
This reference has two entries but the second one is not numbered (it uses the ‘Reference (no
number)’ style.
[2] Another reference
[3] More references
25

Sharma 2019 J. Phys. Conf. Ser. 1240 012030

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sharma 2019 J. Phys. Conf. Ser. 1240 012030

Uploaded by

Copyright:

Available Formats

Journal of Physics: Conference Series

PAPER • OPEN ACCESS You may also like

farm equipment manufacturing - MSME (Micro Small Medium Enterprise)

- The Benefits of Energy Efficiency in Small

View the article online for updates and enhancements.

This content was downloaded from IP address 49.206.20.247 on 30/12/2021 at 07:11

An Intelligent Simulation based case study of Indian Micro

Janpriy Sharma1, Arvind Jayant2

2.1. Micro Small Medium Enterprise (MSMEs)

Figure 1 Classification of MSMEs of India

Figure 2 Research Methodology

3.1 System analysis of Company - Gahir Agro Industries

4. Laser Land Leveller

Figure 3 Laser Land Leveller (Manufactured by Gahir Agro Industry)

4.1 Components in Laser Land Leveller

4.2 Working of Laser Land leveller

Figure 6 Working of Laser land leveller

5. Technical Specifications of Laser land leveller

5.1 Manufacturing process of laser land leveller

6 Modelling and Simulation

6.1 Modelling and Simulation Tool – ARENA Overview

Figure 8 Simulation process – Overview

7 Case Study: Modelling And Simulation Of Laser Land Leveller Process

7.1 Assumptions for modelling and Simulation

Table 1. Modelling logic of various manufacturing process

START Raw material arrival at

Processing begins on raw material Plasma Cutting Sheet

Assembling and Request made for processed Tractor arrives

Manufactured Required raw material

Request made for processed Tractor arrives

Shop Exit taken CURVO / Draw bar

Manufactured CURVO/ Required raw material

Final assembly begins on Shop Final Assembly MAST

Request made for finished Tractor arrives Shop Exit taken

Finished Product moved to

7.2 Modelling and Simulation of manufacturing of Laser Land Leveller Processes

7.2.1 SCRAPPER/BUCKET MANUFACTURING

Table 2 Detail of Operation performed for Scrapper/Bucket Manufacturing

Operation Operation Name Operation Resources deployed

1 Plasma Sheet Cutting 3.5 hours Single Plasma Cutting

Table 3 Inter Shop station distances for Scrapper/Bucket Manufacturing

Sr. No. Station Name (From) Station Name (To) Distance

1. Arrival Dock Plasma Cutting Area 200

Table 4 Data related to Costing of Entity

Name of Entity Holding Cost/Hour Initial value-added Initial trans Cost

Laser Land 1.2 1100 1.3

Figure 9 ARENA window depicting costing data of entity

Figure 10 ARENA window depicting complete model of Scrapper Bucket manufacturing

7.2.2 CURVO/DRAWBAR MANUFACTURING

Table 5 Detail of Operation performed for CURVO/ Draw Bar Manufacturing

Operation No. Operation Name Operation Timing Resources deployed

1 CURVO Mounting 3.2 hours per piece Pre-Assembled Curvo

3. Painting 2.3 hours 4 Painting spray guns

Sr. No. Station Name (From) Station Name (To) Distance

Figure 11 ARENA window depicting distance between shops

Figure 12 ARENA window depicting modelling for CURVO/Draw bar manufacturing

7.2.3 Final Assembly and Mast Mounting

Table 7 Detail of Operation performed for Final Assembly and Inspection

Operation Operation Name Operation Timing Resources deployed

1 Overall Assembly 2.5 hours per piece Assembly and Inspection

2. Mast Mounting 2 hours per piece Pre-assembled mast

Sr. No. Station Name (From) Station Name (To) Distance

1. Arrival Dock Draw bar and CURVO 200